Air horn for efficient fluid intake

ABSTRACT

A method, device, and system for controlling a flow of a fluid moving through a pipe are presented. The device includes a truncated cone having a first diameter at an inlet and a second diameter at an outlet and a bracket attached to the truncated cone. The first diameter of the truncated cone is larger than the second diameter. The bracket is a curved sheet positioned around at least a part of the truncated cone and having an adjustable bracket diameter. The bracket diameter is measured from a center axis extending through a center of the truncated cone. Attaching the device to a fluid flow pipe reduces turbulence in the flow through the pipe, allowing a more streamlined fluid exit from the pipe. When used with an air intake pipe for an internal combustion engine, the device allows more horsepower and mileage to be extracted from the engine.

FIELD OF THE INVENTION

The invention relates generally to a system and method for directing afluid flow and in particular to a system and method for directing afluid in an internal combustion engine.

BACKGROUND OF THE INVENTION

It is well known that internal combustion engines require a flow of airto operate. In particular, the air and fuel are mixed together and thenignited to generate energy which translates into power, for example, tomove a piston up. An internal combustion engine may be used for avariety of different purposes that involve energy generation, includingbut not limited to powering a vehicle. The performance of the engine isaffected by various factors such as the composition of the air, themanner (e.g., velocity) in which the air is supplied to the internalcombustion engine, and the temperature and pressure of the air supply.

Enhancing the performance of an internal combustion engine entailsgenerating more horsepower and/or getting more mileage out of a givenamount of fuel supply. One way to enhance the performance of an internalcombustion engine is to adjust the temperature and the amount of airbeing supply. For example, an automobile may be “turbo charged,” inwhich the incoming air is compressed and then fed into the internalcombustion engine. The turbo charging of an internal combustion engine,however, is expensive and difficult to install for anyone other than anexperienced mechanic. A less expensive option is to attempt to lower thetemperature of the incoming air flow while at the same time increasingthe air flow. This can be accomplished using after-market add oncomponents which replace the original gas intake pipe. One example of aknown system is made by AEM Power, Inc. (http://www.aempower.com).According to AEM Power, this system creates multiple frequency soundwaves to help charge the cylinders with air in the upper engine RPMregion. According to AEM Power, a shorter secondary pipe generates highfrequency sound waves with higher engine RPMs and the smaller, longerprimary pipe generates lower frequency sound waves at lower engine RPMs.This system does result in an increase in engine horsepower and torque.However, the horsepower and torque gain from the AEM V2 Intake Systemcan still be further increased.

Thus, it is desirable to provide a method and device that allows theextraction of more horsepower and mileage out of a given amount of fuelsupply.

SUMMARY

In one aspect, the invention is a device for controlling a flow of afluid moving through a pipe. The device includes a truncated cone havinga first diameter at an inlet and a second diameter at an outlet and abracket attached to the truncated cone. The first diameter of thetruncated cone is larger than the second diameter. The bracket is acurved sheet positioned around at least a part of the truncated cone andhaving an adjustable bracket diameter. The bracket diameter is measuredfrom a center axis extending through a center of the truncated cone.

In another aspect, the invention is a fluid flow system that includes apipe through which the fluid flows and the above device for controllingthe flow of a fluid moving through the pipe.

In yet another aspect, the invention is a method of controlling a fluidflow through a pipe. The method includes attaching a truncated cone toan exit end of the pipe, intaking the fluid through an inlet of thetruncated cone, wherein the inlet has a first diameter, and exiting thefluid through an outlet of the truncated cone. The outlet has a seconddiameter that is smaller than the first diameter.

The invention also includes method of making a device that controlsfluid movement through a pipe. The method includes forming a truncatedcone having a first diameter at an inlet and a second diameter at anoutlet, and forming a bracket around the truncated cone. The firstdiameter is larger than the second diameter. The bracket is a curvedsheet positioned around at least a part of the truncated cone and havingan adjustable bracket diameter, wherein the bracket diameter is measuredfrom a center axis extending through a center of the truncated cone.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating a typical gas directing manifold;

FIG. 2 is a diagram illustrating a typical arrangement of an air intakepipe and the gas directing manifold;

FIG. 3 is a perspective view of an air horn that is designed to fit withthe air intake pipe of FIG. 2 according to the invention.

FIG. 4 is a view from one end of the air horn looking into the air horn.

FIG. 5 is a side view of the air horn.

FIG. 6 is a diagram of the air horn in combination with the air intakepipe.

FIG. 7A is a cross section of the air intake pipe showing the airflowthrough the air intake pipe in the absence of the air horn.

FIG. 7B is a cross section of the air intake pipe showing the airflowthrough the air intake pipe when the air horn is positioned near theoutlet of the air intake pipe.

FIG. 8 is a cross sectional view of the interface between the air intakepipe and the air horn, and shows the flow of air through the air horn.

FIG. 9 is a perspective view of an air horn that is designed to fit withthe air intake pipe according to a second embodiment of the invention.

FIG. 10 is a cross section of the air intake pipe showing the airflowthrough the air intake pipe when the air horn is positioned near theintake end of the air intake pipe.

FIG. 11 is a cross sectional view of the interface between the airintake pipe and the air horn placed at the intake end of the air intakepipe.

FIG. 12 is a cross sectional view of an air intake pipe having both anair horn of the first embodiment and an air horn of the secondembodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

The invention is particularly applicable to an air intake pipe for aninternal combustion engine, such as a vehicle engine, and it is in thiscontext that the invention will be described. It will be appreciated,however, that the air intake pipe and method in accordance with theinvention has greater utility since it may be used with variousdifferent fluids for various different purposes, and is not limited touse with only air.

FIG. 1 is a diagram illustrating a typical internal combustion engine30. In particular, FIG. 1 illustrates a typical internal combustionengine 30 with a typical gas directing manifold 32 and a typical exhaustmanifold 34, as are well known. The gas directing manifold 32 providesair into the internal combustion engine so that it can be mixed withfuel and ignited while the exhaust manifold 34 generates a slight backpressure and exhausts the exhaust gases out of the internal combustionengine 30.

FIG. 2 is a diagram illustrating an air intake pipe 40 that is arrangedto supply air to the gas directing manifold 32 of FIG. 1. The air intakepipe 40 fits onto a typical gas directing manifold 32 through a throttlebody 31 so that a fluid (e.g., air) exiting the air intake pipe 40enters the internal combustion engine 30 in this embodiment. The airintake pipe 40 directs the air from an air box (not shown) to the gasdirecting manifold 32, as shown by the arrows. The gas intake pipe 40has a center axis 41 extending through the center of every circularcross section along its length.

FIG. 3 is a perspective view of an air horn 50 that is designed to fitwith the air intake pipe 40 to control the air flow into the gasdirecting manifold 32 according to a first embodiment of the invention.Specifically, this first embodiment is designed to fit at the exit endof the air intake pipe 40. If the internal combustion engine 30 is in avehicle, increasing the velocity of the air flow results in increasedhorsepower and higher gas mileage per fuel volume for the vehicle. Asshown, the air horn 50 has the general shape of a truncated cone 52, ora cone with the pointed end truncated off. Thus, an inlet 54 and anoutlet 56 have different diameters. To achieve the increase in airvelocity, the inlet 54 is of a larger diameter than the outlet 56. Thetruncated cone 52 has a center axis 51 extending through the center ofits every circular cross section.

A bracket 58 is formed around the truncated cone 52. The bracket 58 isdesigned so that its diameter is adjustable, its purpose being to allowthe air horn 50 to securely fit with air intake pipes of differentsizes. The truncated cone 52 and the bracket 58 may be made of the samematerial or different materials. The diameter of the bracket 58 (asmeasured from the center axis 51) is adjusted by moving a first end 65and a second end 66 of the curved sheet closer together, in thedirection shown by the arrow 59. When no force is applied to the airhorn 50, the bracket 58 is in its “natural” state where the first end 65is separated from the second end 66 by a certain distance. In theembodiment shown, the first end 65 is fixed in its position by a prong60, and the second end 66 is free to move closer to the first end 65.The bracket 58 is made of a material that is hard enough to sustain itsshape but flexible enough that the second end 66 can be moved closer tothe first end 65 by applying an inward pressure. The material making upthe bracket 58 has a memory such that when it is in the “squeezed”state, it wants to revert back to the natural state. Thus, when thebracket 58 is fit into a pipe in the “squeezed” state, the outward forcecreated by the bracket's desire to expand back to its natural statesecurely fixes the air horn 50 to the pipe. Exemplary materials that aresuitable for the truncated cone 52 and the bracket 58 include stainlesssteel, aluminum, and injected plastic.

FIG. 4 is a view from one end of the air horn 50 looking into the airhorn 50. In the embodiment shown, the bracket 58 is attached to thetruncated cone 52 with prongs 60. Although the invention is not limitedto a certain number of prongs 60, the prongs 60 provide a secureattachment of the bracket 58 to the cone 52 while allowing the diameterof the bracket 58 to be adjusted by “squeezing” the bracket 58 to movethe loose end of the bracket sheet in the direction indicated by thearrow. In this embodiment, the prongs 60 connect the inner surface ofthe bracket 58 to the outer surface of the truncated cone 52.

FIG. 5 is a side view of the air horn 50. The side view shows that thetruncated cone 52 has a lip 62 at the intake end 54 to help gather moreair for intake. A flange 64 located at an edge of the bracket 58 that isclosest to the output end 56 controls how much of the air horn 50 isinserted into the air intake pipe 40 by stopping the insertion. Anyconventional type of safety mechanism other than the flange 64 may beused either in place of or in addition to the flange 64 to ensure that auser will not push the entire air horn 50 into the gas intake pipe 40too deep, making it difficult to remove the air horn 50 later.

FIG. 5 also shows that the prong 60 is longer than the bracket 58 whenmeasured in the direction of the center axis 51. This is a designdecision specific to the shown embodiment that provides extra securityto the attachment of the bracket 58 to the truncated cone 52, and is nota limitation of the invention.

FIG. 6 is a diagram of the air horn 50 in combination with the airintake pipe 40. As shown, the air horn 50 is positioned near the outletof the air intake pipe 40, near the interface between the air intakepipe 40 and the gas directing manifold 32. Preferably, the center axis41 of the air intake pipe 40 and the center axis 51 of the air horn 50are aligned when the two pieces are combined. Typically, the diameter ofan air intake pipe 40 is between the ranges of about 2 inches and 4inches. The air horn 50 is designed to fit securely into the air intakepipe 40. Generally, the longer the air horn 50 and the greater thedifference is between the inlet diameter and the outlet diameter, themore dramatic the effect will be of the horsepower increase that isachieved. However, because the air horn 50 is designed to be positionedin the space between the air intake pipe 40 and the gas directingmanifold 32, it can only be made so long. The air horn 50 is preferablyas long as it is allowed to be given the space constraints.

FIG. 7A is a cross section of the air intake pipe 40 showing the airflowthrough the air intake pipe 40 in the absence of the air horn 50. Asshown by the arrows, air passing through the air intake pipe 40experiences much turbulence, and the flow is not streamlined. Theturbulence inside the air intake pipe 40 results in inefficient feedingof air to the gas directing manifold 32 through the throttle body 31,which compromises the horsepower output of the internal combustionengine 30.

FIG. 7B is a cross section of the air intake pipe 40 showing the airflowthrough the air intake pipe 40 when the air horn 50 is positioned nearthe exit end of the air intake pipe 40. As shown, the air flow throughthe air intake pipe 40 is streamlined when the air horn 50 is added tothe air intake pipe 40. The air horn 50 decreases the turbulence in theair flow through the air intake pipe 40 and allows a more efficientfeeding of the air to the gas directing manifold 32.

FIG. 8 is a cross sectional view of the interface between the air intakepipe 40 and the air horn 50 placed at the exit end of the intake pipe40, and shows the flow of air through the air horn 50. As shown byarrows 68, the lip 62 at the edge of the truncated cone 52 pulls in airthat would have otherwise flowed outside the truncated cone 52 throughthe gap 70. Thus, the lip 62 increases the amount of air that is forcedthrough the truncated cone 52. The narrowing of the cone diameter as theair flows through the cone 52 results in the air velocity increasing asit approaches the outlet end 56. This increase in air velocity creates alower pressure near the outlet end 56 than at the inlet end 54, and thispressure difference “pulls” more air through the air horn 50 and intothe internal combustion engine 30. As a result, the overall air flowrate through the air intake pipe 40 is increased, resulting in thegeneration of increased horsepower.

The air flow that does not enter the truncated cone 52 is guided throughthe gap 70 between the bracket 58 and the outer surface of the truncatedcone 52, partly guided by the Coanda effect around the curves of the lip62. Due to the sloping of the truncated cone's sidewall, the gap 70 getsbigger through the length of the air horn 50. Due to this increase inthe gap 70, the velocity of the air that travels through the region 70decreases as it travels through the gap 70. As a result, the velocity ofthe air in the region 70 near the outlet end 58 is slower than thevelocity of the air exiting the truncated cone 52. According toBernoulli's principle, the pressure of the slow-traveling air in the gap70 near the outlet end 56 is higher than the pressure of thefast-traveling air exiting the truncated cone 52. This pressuredifference results in the air flow being “forced” toward the center axis41, streamlining the flow and “shooting” the air into the internalcombustion engine 30 in more focused manner than if there were no airhorn 50. Due to the fast-traveling air coming out of the outlet 56, theoverall velocity of the air that is fed to the gas directing manifold 32is faster than if there were no air horn 50. The overall effect of this“shooting” is increased horsepower generation and an improved gasmileage per fuel supply volume.

In an exemplary embodiment, the inner diameter at the inlet 54 is about½ inch larger than the diameter at the outlet 56. Some exemplarydimensions of the air horn 50 are summarized in the following table:Pipe size Inlet diameter Outlet diameter (pipe diameter in inches)(inches) (inches) 2.5˜2 1.5 1 2.5˜3 2 1.5   3˜3.5 2.5 2 3.5˜4 3 2.5

FIG. 9 is a perspective view of an air horn 50 that is designed to fitwith the air intake pipe 40 according to a second embodiment of theinvention. Specifically, this second embodiment is designed to fit atthe intake end of the intake pipe 40. Like the air horn 50 of the firstembodiment, the air horn 50 of the second embodiment has the truncatedcone 52 and an inlet 54 and an outlet 56 that have different diameters.Also, like the air horn 50 of the first embodiment, the air horn 50 ofthe second embodiment has the bracket 58 that is attached to thetruncated cone 52 with at least one prong 60. The bracket 54 in thissecond embodiment is similar to the bracket 54 of the first embodimentexcept that the flange 64 is located at the edge of the bracket 54 thatis nearest the inlet 54 not nearest the outlet 56 as in the firstembodiment.

FIG. 10 is a cross section of the air intake pipe 40 showing the airflowthrough the air intake pipe 40 when the air horn 50 is positioned nearthe intake end of the air intake pipe 40. As shown, placing the air horn50 at the intake end of the air intake pipe 40 streamlines the air flowthrough the pipe similarly to when the air horn 50 is placed at the exitend of the air intake pipe 40 (see FIG. 7B). The flange 64 locatedcloser to the inlet 54 than the outlet 56 of the truncated cone 52 stopsthe air horn 50 from getting pushed too far into the air intake pipe 40.Had the first embodiment of the air horn 50 been used at the intake endof the air intake pipe 40, the air horn 50 would not have been pushed infar enough to be secure. This second embodiment of the air horn 50 maybe especially useful when it is inconvenient to place the air horn 50between the throttle 31 and the air intake pipe 40 because of spacelimitations. In some situations, it may be desirable to use two airhorns—one at the intake end of the intake pipe 40 and another one at theexit end of the intake pipe 40, as shown in FIG. 12.

FIG. 11 is a cross sectional view of the interface between the airintake pipe 40 and the air horn 50 placed at the intake end of the airintake pipe 40. The air flow through the air horn 50 is similar to theair flow that is seen when the air horn 50 is placed near the exit endof the air intake pipe 40. The high-velocity air exiting the truncatedcone 52 meets the low-velocity air coming out of the gap 70 and shoots acombined stream of air near the center axis 41 of the air intake pipe40. This combined, focused stream of air results in a more effectivefeeding of the air into the gas directing manifold 32, as explainedabove, increasing the horsepower generated from the internal combustionengine 30.

While the foregoing has been with reference to a particular embodimentof the invention, it will be appreciated by those skilled in the artthat changes in this embodiment may be made without departing from theprinciples and spirit of the invention. For example, the air horndisclosed herein may be used with any types of intake pipe other thanone that is part of an automotive system. The scope of the invention isdefined by the appended claims.

1. A device controlling a flow of a fluid moving through a pipe, thedevice comprising: a truncated cone having a first diameter at an inletand a second diameter at an outlet, wherein the first diameter is largerthan the second diameter; and a bracket attached to the truncated cone,wherein the bracket is a curved sheet positioned around at least a partof the truncated cone and having an adjustable bracket diameter, whereinthe bracket diameter is measured from a center axis extending through acenter of the truncated cone.
 2. The device of claim 1, wherein thebracket is a curved sheet that is partially formed around the truncatedcone, and wherein the bracket diameter is adjustable by controlling adistance between a first end of the curved sheet and a second end of thecurved sheet.
 3. The device of claim 1, wherein the first end of thecurved sheet is fixed to the truncated cone and the second end is freeto be moved to and away from the first end.
 4. The device of claim 1further comprising a flange protruding from the bracket.
 5. The deviceof claim 4, wherein the flange is positioned on an edge of the bracketthat is closest to the outlet of the truncated cone.
 6. The device ofclaim 4, wherein the flange is positioned on an edge of the bracket thatis closest to the inlet of the truncated cone.
 7. The device of claim 1,wherein the truncated cone has a lip at the inlet to increase the amountof fluid that passes through the truncated cone.
 8. The device of claim1, wherein the first diameter is about 0.5″ larger than the seconddiameter.
 9. The device of claim 1, wherein the truncated cone and thebracket are made of the same material.
 10. The device of claim 8,wherein the same material is one of aluminum, stainless steel, andinjected plastic.
 11. The device of claim 1, wherein the device isdesigned to partially fit into the pipe and securely attach to the pipe.12. A fluid flow system comprising: a pipe through which the fluidflows; a device for controlling a flow of the fluid moving through thepipe, wherein the device is attached to an end of the pipe, the devicehaving: a truncated cone having a first diameter at an inlet and asecond diameter at an outlet, wherein the first diameter is larger thanthe second diameter; and a bracket attached to the truncated cone,wherein the bracket is a curved sheet positioned around at least a partof the truncated cone and having an adjustable bracket diameter, whereinthe bracket diameter is measured from a center axis extending through acenter of the truncated cone.
 13. The system of claim 12, wherein thedevice is attached to an exit end of the pipe.
 14. The system of claim13, wherein the device is a first device, further comprising a seconddevice substantially similar to the first device attached to an intakeend of the pipe.
 15. The system of claim 12, wherein the device isattached to an intake end of the pipe.
 16. A method of making a devicethat controls fluid movement through a pipe, the method comprising:forming a truncated cone having a first diameter at an inlet and asecond diameter at an outlet, wherein the first diameter is larger thanthe second diameter; and forming a bracket around the truncated cone,wherein the bracket is a curved sheet positioned around at least a partof the truncated cone and having an adjustable bracket diameter, whereinthe bracket diameter is measured from a center axis extending through acenter of the truncated cone.
 17. The method of claim 16 furthercomprising making the bracket diameter adjustable by fixing a first endof the curved sheet to the truncated cone and leaving a second end ofthe curved sheet free to be moved to and away from the first end of thecurved sheet.
 18. The method of claim 16 further comprising forming aflange protruding from the bracket.
 19. The method of claim 15, whereinthe flange is formed on an edge of the bracket that is closest to theoutlet of the truncated cone.
 20. The method of claim 15, wherein theflange is formed on an edge of the bracket that is closest to the inletof the truncated cone.
 21. The method of claim 16 further comprisingmaking the first diameter about 0.5″ larger than the second diameter.22. The method of claim 16 further comprising forming a lip at the inletof the truncated cone to increase the amount of fluid that passesthrough the truncated cone.
 23. A method of controlling a fluid flowthrough a pipe, the method comprising: attaching a truncated cone to thepipe; intaking the fluid through an inlet of the truncated cone, whereinthe inlet has a first diameter; exiting the fluid through an outlet ofthe truncated cone, wherein the outlet has a second diameter that issmaller than the first diameter.
 24. The method of claim 23, wherein thetruncated cone is a first truncated cone, further comprising attaching asecond truncated cone to a different location on the pipe.